Fuel Injected 4.9 Engine Swap into 1977 F150

OH... One other thing...Is anyone familiar with the inside to these metal unions built into the 1993 Fuel lines????????? This is where the rear tank supply and return lines merge into the front tank supply and return lines. The two colored lines you can see in the picture are fro the front tank and hooked to nothing. The 93 truck had dual tanks run off the same set of lines to the motor. They tapped into the supply and return in these blocks, well Im not running the second tank and Im curious what it going to happen to the other end of the supply and return line that is left wide open, hooked up to nothing, just laying on the frame. The only thing that controls which tank runs at which time is the manual switch on the dash and there are no other sort of switching valves built into the line. Im making the asumption that there is a one was check valve built into that block where the front tank and rear tank lines meet. There almost would have to be cause you wouldnt want the return fuel heading into the wrong tank.... I would hate for gas to come streaming out of either one. I would cut them open and look inside but they are the only set I have and I need them. Does anyone else know??? Or have some lines they dont mind cutting in half for the sake of myself and other Ford truck owners.....

For '93 each tank has a valve that prevents fuel from being pumped out of either of those lines when that tank isn't selected. With them not hooked up, gas will come out of them. You will need to cap them somehow. I totally forgot about getting the picture of that bracket, I'll see if I can get a good picture of it right now.

I can't get a decent picture without removing the shield around the cables, but it looks pretty simple. Looking from the drivers side, the throttle bracket bolts to the upper and lower left throttle body bolts. Mine's an '87 though, so yours might be different.

For '93 each tank has a valve that prevents fuel from being pumped out of either of those lines when that tank isn't selected. With them not hooked up, gas will come out of them. You will need to cap them somehow. I totally forgot about getting the picture of that bracket, I'll see if I can get a good picture of it right now.

But they shouldnt have as much pressure as the main lines running to the rear tank will they???? Any idea how much fuel or pressure they would see?? Wondering if it would be enough it will cause the pump to have a pressure loss by the time it reaches the engine?? Could I just run them into each other so the supply runs into the return???

I'm not sure if hooking them together will work. The feed line will get full fuel pump pressure and starve the engine for fuel if it's not capped. The return line will get full return pressure. I think I would cut them off at the tee where they're steel. Get fuel injection rubber fuel line and fuel injection clamps, they are different from regular fuel hose and clamps. Use that to cap off the lines, along with some kind of cap. There are single tank trucks, if you can find one then you can get the union that fits there from one or try to get it from the dealer.

Sean I was initially hesitant to believe there was no valve on that block until I decided to go into Alldata on my shop account and poke around in the description and operation section of the fuel system and youre right it clearly states a check valve inside the tank. Here is Alldata's direct copy and pasted information....... Fuel Pressure Check ValveDescription and OperationDescription and OperationNotesPURPOSE

***AND THERES EVEN A RECALL FOR THE GAS ROLLING OVER FROM ONE TANK INTO THE OTHER.****

Recall - Cross Tank Fuel Flow ConditionNotesRECALL NUMBER: 93S68
Date: Sept. 1993
At Dealers By as Req'd.
At PDC by
Date in Owner Letter
0% of Parts Direct Shipped to Dealers
TO: All Ford Dealers
SUBJECT:
Safety Recall 93S68 - All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks.
AFFECTED VEHICLES
All 1990, 1991, 1992 and certain 1993 model F-series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter engines and dual fuel tanks.
REASONS FOR RECALL
Some of the affected vehicles may experience a cross tank fuel flow condition due to a damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire.
To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank.
FREE FUEL LINE REMOVAL TOOL
Standard fuel line removal tools can be used to disconnect fuel lines. However, because of the number of vehicles to be serviced, two free tools (# T93T-9550-AH) will be provided to each Ford dealer. These tools will be in your next Dealer Mail System (DMS) shipment (DMS packing slip # 930902).

***AND THE CHECK VALVE IS INSTALLED AT THE END OF THE LINE ON THE PUMP INTSELF. THE TECNICAL LETTER DID MENTION NEW LINES THAT HAVE CHECK VALVES BUILT INTO THEM. GEUSS I NEED TO RUN MY VIN AND SEE IF ITS BEEN DONE CAUSE I DONT HAVE ANY SMALL VALVES AT THE TOP OF THE TANK LIKE IN THIS PICTURE.***

11.PRE-POSITION THE SECOND SAFETY CLIP ON THE OTHER END OF THE CHECK VALVE CONNECTOR (IF NOT ALREADY PRE-POSITIONED - SEE NOTE IN STEP # 10).

**I copy and pasted the entire section with pictures into this post right off alldata and it displayed it in my computer screen after posting and when I logged in from a different computer I dont see any pictures, sorry guys, if anyone knows how to fix this feel free to let me know.**

By the way, Sean you need anything off Alldata???? I think Im going to keep the lines I have but take my tubing cutter and cut off the metal supply and return lines on the top of the front tank pump, tig weld the ends so there just a solid plug and snap them in. It should not cause any pressure loss since they will be capped.

No thanks, I can't think of anything I need from Alldata. I'm sure you know what you're doing, but carefully inspect the welds when you're done to make sure there aren't any fuel leaks.

Your pictures aren't showing up because they're copied from that site. Even if you posted them with a web address (I think that's what it's called) they probably won't show up since that's a pay site. The only way to post them would be to copy the pictures to your computer and load them as attachments, load them into an album here and post them, or load them to photobucket or some other image hosting site and post them.

Update pictures..... Got a lot done this past week, I was suprised about how much of a pain in the ***** the header was to install. The issues were mainly a lack of clearence between the header and frame, the bellhousing, and very close around the starter. The starter had to be installed at the same time as the header and the intake had to be unbolted and swung out of the way. The alternator bracket had to be cut and clearenced to clear the primary tube on #1 but that was simple. I also was amazed with how close the fuel injection intake is to the firewall, at most 1/4 of an inch. For the most part everything else slid right into place. I still prolly have another week or so working on this before its running. I can tell fabbing the rest of the exhaust system will be a massive PITA. I can see why they say it only fits a 2wd, the transmission cross member is different and when the header is on a 4wd most guys get lazy and run one pipe over and one under, NOT I, they will both be above but it will take some time. ....... Also could someone post a throttle body bracket picture??? I cant make any sense of what I have, maybe because Ive removed a bunch of stuff I didnt need and its been apart for sooo long.

A few more pictures, the collectors look mean but that is going to be a lot of work to snake both pipes above the transmission cross member. With the header on the same side as the intake all of the tubing on that side looks crazy and farrrrr from stock on that old truck.